designers, manufacturers & turnkey solution providersid fan with vfd wet scrubber fuel...

aswathi industries limited

An ISO 9001:2015 Company

Corporate Office:Apeksha Enclave, Mahavir Nagar,Kandivali (W), Mumbai – 400 067, India.Phone : +91-22-61790900/1/2.Fax : +91-22-61790993.

E-mail : [email protected]: www.aswathiindustries.com

Works :Unit – I : 401(P), Abitghar, Wada Shahpur Road, Thane, Maharashtra, India.Unit – II : 34(P), 36(P) & 39(P), Abitghar, Wada Shahpur Road, Thane, Maharashtra. Tel Nos. : +91-2526-228063/228064Fax No. : +91-2526-228065

Designers, Manufacturers & Turnkey Solution Providers

aswathi industries ltd.An ISO 9001:2015 Company

Products & Solutions

Air Pollution System

Water Treatment PlantIndustrial Furnace & drying

Waste recycling & incineration

We at Aswathi Industries Limited design, manufacture & supply

Lead-acid battery recycling plants. It adapts latest design

techniques for plant design in terms technology, environment

friendly, international standards/practice & quality. Aswathi is

committed to deliver its products with consistency in quality &

reliability.

The scrap/used batteries are the raw material (automotive/

industrial) for recycling process to reclaim the Lead. Aswathi is

committed to provide the sustainable manufacturing process &

operations.

We provide complete Turnkey Solutions for battery recycling

system with the following units:

• Automatic Battery Crushing & Hydro separation unit,

• Acid neutralisation,

• Desulphurization ,

• PP Recycling,

• Smelting unit which uses Rotary Furnace with APC System,

• Refining Section with APC System to produce pure/Lead alloy.

• Ingot Casting Machine for refined/lead alloy as final product.

• Consultancy services for process improvements &

refurbishment of plant & machineries.

Lead Acid Battery Recycling System


We offer Integrated Solution to set up the Scrap Battery Recycling

facility which includes the following:

Automatic Battery Crusher with Hydro separation unit.

Acid Neutralisation System.

Desulphurisation System.

Crystallisation/salt recovery system.

Smelting System with APC System.

Material Handling Equipment.

Refining unit with APC System.

Automatic Ingot Casting Machine.

Auto Stacking Machine.

Engineering Services for Infrastructure Building.

Technical Assistance for Process improvement, Plant up gradation.

Support for Plant Erection & Commissioning.

Automatic Battery Crushing & Hydro-separation.

The basic principle of Battery Crushing and Hydroseparation unit is to crush the battery in a closed chamber by impact of rotating Hammers & segregationof metallic lead, Separatorand PP/PE by Sink & floatmechanism. The productsfrom the Crusher are as

Shown in figure.

Lead Acid Battery Recycling System



Acid Neutralisation:

System is provided with Acid neutralisation unit to

neutralise the acidic water. As & when recirculation water

becomes acidic, is transferred to neutralisation tank where

Lime Solution is added and agitated for proper mixing &

neutralisation. The neutralised solution then passed

through Filter Press to Separate the Calcium Sulphate &

Water. The water is recirculate into process & Calcium

Sulphate is being stored/disposed off.

Fume Scrubbing:

The acidic fumes/mist

generated during battery

crushing are collected from

Battery Crusher, Reaction

Tanks & Vibrating Screens.

These are collected through

non metallic pipelines with

ID Fan and treated at

scrubber. At Scrubber, water

is being circulated through

Nozzles to form droplets /

mist to trap the acidic

fumes. The cleaned gas is

is discharged through vent

from Scrubber.


We provide fixed axis Rotary Furnace to recover the lead

from metal bearing materials separated out at Battery

crusher. Necessary chemical reactions takes place at Rotary

Furnace in presence of reagents at high temperature to

remove the Oxygen and Sulphur elements, which is

reduction process. Wood charcoal or Petroleum Coke (Coal)

is the most commonly used reducing agents in the lead

recycling industry. The Flow Chart of the same as shown:

Settling Chamber

Dust Laden flue gases

Cyclone

Rotary Furnace

SMELTING PROCESS FLOW CHART

Exhaust Gases from

Rotary Furnace Casting Trolley

Cooling Tower

Dust Collector

Charge & Reagents

ID Fan with VFD Wet Scrubber

Fuel Combustion Air

Molten Lead

to Ladles Slag

Dust – Coarser Particles

Dust – Coarser to Medium

Dust – Medium to Fine

Dust – Medium to Fine

B. H. Modules

Chimney

Feed

to

Rotary

Furnace

mixing

with

Charge

Flue gases

Dust – Fine in nature

Acidic Water for neutralisation

Clean gases to Atmosphere

Flue gases @ 100-110 ◦ C

Rotary Enclosure

Twin Cyclones

Fumes from Hood

Dust Particles

Smelting Processwith APC System:


Key feature of Our Smelting unit with APC:

Fixed axis type Rotary Furnace .

Combustion System - Burner suitable for solid / liquid / gas.

Charging mechanism as per customer need.

High Efficiency Dust Collection System.

OFF Line Filter Bags for better dust collection

PTFE Laminate over Polyester bags for better filtration.

Knocker at all dust collection points to avoid accumulation.

Closed BHP/Powder collection & storage arrangement.

Packed bed Scrubber for SO2 scrubbing.

pH measurement & indication.

Auto Caustic Dosing arrangement.

Combined Fugitive Emission System.

Hoods at Charging/tapping point to collect vapors/fumes

during Charging /Metal/Slag tapping.

Control Automation - PLC with SCADA with safety

interlocks, data collection/storage, trends (Optional).

Zero Liquid discharge system as a result of neutralisation,

no toxic liquid generation/discharge.

Follows the Best Available Technique for plant design.


Refining Processwith APC System:

We design & supply the system required to process the lead

bullion to produce pure/alloy by removal of unwanted

impurities . Each refining kettle is equipped with an air-fuel

burner for melting the lead bullion and keeps the lead bath

at the required temperature. The refining of lead is a pyro-

metallurgical process and removal of different elements is

done by the addition of reagents at proper temperature and

severe agitation of lead bath.

Air Pollution Control system - Refining Furnace is provided

with hygiene hood to ensure the vapors/fumes generated

during the process are collected and treated before let into

atmosphere. System is provided with Cyclone followed by

Bag House to ensure the complete collection of particulate

matters. Similarly Venturi Scrubber is provided on flue gas

line to neutralize the acidic fumes before letting them into

atmosphere.

Ingot Casting Machine - refined or alloyed finished lead is

casted in the form of ingots of weight around 25 Kgs in cast

iron moulds on ingot casting machine which are cooled by

water spray and blow of air. The molten refined or alloyed

lead is feed to casting machine from kettle by gravity/pump.

Distributor is provided for molten lead feed to moulds.

Water Cooling arrangement is provided to allow to solidify

the molten Lead. The ingots are hammered to release from

moulds & sent for stacking/strapping.


Process Flow Diagramof Battery Recycling Plant


INCINERATION

SYSTEM

We design Incineration System suitable to handle the following typeof wastes:

• Industrial Hazardous Waste• Liquid (Organic & Aqueous),• Solid, Semisolid, Tarry Wastes.• Gaseous/VOC/Fumes.• Hospital/Biomedical Wastes.

• Trash/Garbage/Canteen Waste

• Stationary Type Incineration Systems.

• Rotary Kiln type Incineration System:

• Pyrolysis type Incineration System

• Thermal Oxidizer• Spray Incineration

Types of Incineration Systems can be offered based on nature ofwastes:

• Dryers for Chemical, Mineral, Ferrous & Non-ferrous components (Fuel Fired & Electrical).

• Tray Dryers, Continuous & Conveyorized Dryers(Fuel Fired & Electrical).

• Rotary Kilns & Rotary Dryers-Direct & In-Direct Fired(Fuel Fired & Electrical).

• For Drying, Calcination, Roasting & Reduction, Continuous as well as Batch type indirect fired with SS 310& Inconel Shell


ROTARY KILNS & DRYERS

BAG FILTER SYSTEMS

REVERSE AIR BAG HOUSE

ELECTRO STATIC

PRECIPITATORS (ESP)

CONVERSIONS OF ESPs TO

BAG FILTERS/HYBRID FILTERS

RETROFITTING & UPGRADATION OF ESP

CYCLONES & MULTICLONES

INDUSTRIAL FANS


AIR POLLUTION CONTROL EQUIPMENT


• Dust extraction System for Cement Plants.

• Dust/Fume Extraction Plants forFerrous & Non Ferrous Industry.

• Fume Scrubbing System for Electronic & Optical fiber Industry.

• Dust/Fume Cleaning System for Chemical, Paper, Pulp and Pharmaceutical & other Industries.

• Dust Collection System for material handling application.

• Dust Collection System forBoiler Application.

TURNKEY SYSTEMS FOR AIR POLLUTION CONTROL


Types- I.D. Fans, S.A Fans, F.D Fans, Centrifugal Fans, Bag filter Fans, Scrubber Fans, Fume Extraction Fans, Cooling Fans, Exhaust Fans, Combustion Air Fans, Pilot Air Fans, High & Medium Pressure Fans etc.

Industry- Cement Plants,Chemical Plants,Steel Plants,Galvanizing Plants,Power Plants,Furnace Industry,Ceramic Industry etc.

.

INDUSTRIAL FANS


Clarifiers

Clarrifloculators

Slurry Hydrate Flow Regulators

Dual Media Filters

Filtrate Receiver & Moisture Trap

HRB Reactors

Cinemud Filter Sugar Industries.

Sludge thickeners

Aerators

WATER TREATMENT PLANT

PYROLYSIS PLANT

Pyrolysis Plant system comprising of:

• Feeding Arrangement.

• Shredder.

• Silo

• Indirectly Heated Rotary Calciner

• Isolation Chamber

• Jacketed Screw Cooler

• Magnetic Separator

• Vertical Screw Conveyor


• All types of non-ferrous melting furnaces with continuous casting & other accessories.

• Walking Beam Furnace.

• Roller Hearth Furnace.

• Pusher Type Furnace.

• Silicon Carbide and Super

Kanthal Furnaces.

• Aluminum Melting Furnaces.


HEAT TREATMENT FURNACES

WALKING BEAM FURNACE


DIRECT FIRED ROTARY CALCINER

ROTARY DRYER FOR CASTING SAND


ELECTRICAL PANELS

CONTROL PANELS


PERFORMANCE TESTING OF

FANS

CNC PLASMA CUTTING

MACHINE

DYNAMIC BALANCING

MACHINEAXIAL FAN

MACHINERIES &

TESTING FACILITY

SIDE SUCTION DRAFT HOOD & MOTORIZED

SWIVEL BEARING ARRANGEMENT


SCRUBBER FORCED DRAFT COOLER

WATER COOLED HOOD & DUCT LADDLE & BAIL ARM WITH

J-HOOKS


APC EQUIPMENTS

• Alps Environmental Engg. Ltd.

• BARC, Trombay

• Batliboi Environmental Engg. Ltd.

• Bharat Heavy Electricals Ltd.

• Essar Constructions Ltd.

• Envac Environmental Technology

Pvt. Ltd.

• F.L. Smidth

• Fives Solios

• GL & V India Pvt. Ltd.

• Hindustan Dorr-Oliver Ltd.

• Lizer Cylinder Ltd.

• NALCO

• Philips Carbon Black Ltd.

• Rubamin Ltd.

• Shriram Engg. Const. Company Ltd.

• Sudharshan Chemical Engg. Pvt. Ltd.

• Sud Chemie India Pvt. Ltd.

• Tata Chemicals Ltd.

• Tata Metalinks Ltd.

• Thermax India Ltd.

• United Phosphorus Ltd.

• Bharuch Enviro Infrastructure LTD


DOMESTIC CLIENTS

• Agrani Aluminum Pvt. Ltd., Nepal

• AHI Roofing’s Ltd., New Zealand

• BA Industries, Fiji

• Cantrex, Port of Spain

• CMRDI, Egypt

• Envac Middle East FZE, Dubai

• Envac Dubai LLC, Dubai

• Envac Saudi Arabia LLC, S.A.

• Eiffel Aluminium Factory, Qatar

• Kenya Fluspar Ltd, Kenya

• Kalu Works, Kenya

• Mombasa Cement, Kenya

• R.K. Metal, Malaysia


OVERSEAS CLIENTS

• Agrani Aluminum Pvt. Ltd., Nepal

• AHI Roofing’s Ltd., New Zealand

• BA Industries, Fiji

• Cantrex, Port of Spain

• CMRDI, Egypt

• Envac Middle East FZE, Dubai

• Envac Dubai LLC, Dubai

• Envac Saudi Arabia LLC, S.A.

• Eiffel Aluminium Factory, Qatar

• Kenya Fluspar Ltd, Kenya

• Kalu Works, Kenya

• Mombasa Cement, Kenya

• R.K. Metal, Malaysia,

• Enviro Hem, Spain.

• Heidelberg Cement Bangladesh Ltd.,

• Wassaif Al Ganoub Steel Factory, KSA, Riyadh ,

• Pushpit Steels Pvt. Ltd., Nigeria.

• Habesha Steel Mill Pvt. Ltd., Ethiopia.

• Top Steel Limited, Nigeria,

• Real Steel Nigeria Limited, Nigeria.

• Techno Asphalt (Pty.) Ltd., Western Cape, South Africa,

• Camso Loadstar (Pvt.) ltd., Srilanka,

• Ceyquartz MBI (Pvt.) Ltd. , Srilanka.

• Jindal UAE ,

• Pan Gulf Metals & Minerals Trading L.L.C, Dubai.


Overseas Clients

• Alps Environmental Engg. Ltd.

• BARC, Trombay

• Batliboi Environmental Engg. Ltd.

• Bharat Heavy Electricals Ltd.

• Essar Constructions Ltd.

• Envac Environmental Technology Pvt. Ltd.

• F.L. Smidth

• Fives Solios

• GL & V India Pvt. Ltd.

• Hindustan Dorr-Oliver Ltd.

• Lizer Cylinder Ltd.

• NALCO

• Torane Ispat Udyog Pvt. Ltd. -Wada, Thane

• Philips Carbon Black Ltd.

• Rubamin Ltd.

• Shriram Engg. Const. Company Ltd.

• Sudharshan Chemical Engg. Pvt. Ltd.

• Sud Chemie India Pvt. Ltd.

• Tata Chemicals Ltd.

• Tata Metalinks Ltd.

• McNally Bharat - NTPC (Through OEM)

• Thermax India Ltd.

• United Phosphorus Ltd.

• FFE Minerals Pvt. Ltd., Vedanta Project (Through OEM)

• GEA Process Engineering India (P) Ltd.


Domestic Client List

INSPECTION

THIRD PARTY INSPECTION AGENCIES

Avant-Garde Engineers and Consultants (P) Ltd.

Bureau Veritas

DNV

E.I.L

M.N Dastur & Company Ltd.

Macon Ltd.

Profen Engineering

Tata Projects

UHDE India Ltd.


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